Processing cartons for packaging thereof



May 5, 1970 E. A. HARTBAUER ETAL 3,509,688

PRCESSING GARTONS FOR PACKAGING THEREOF' l Filed April 24. 1967 1.5 Sheets-Sheet 1 nu s u wsu, llslellll; H Jfv Nw v w wm L QN. Nw km.

-..SK fr. J1 \f JN & f .J1 NQwb m N26 bwub Qab ha NSEM May 5, 1970 E. A. HARTBAUER l-:TAL` 3,509,688

PROCESSING CARTONS FOR PACKAGING THEREOF Filed April 24. 1967 15 Sheets-Sheet a May 5, 1970 E. A. HARTBAUER ETAL 3,509,688

PRocEssING cARToNs FOR PACKAGING vTHEREOF Filed April 24. 1967 l5 Sheets-Sheet 5 May 5, 1970 E. A. HARTBAUER ETAL 3,509,688

PROCESSING CARTONS FOR PACKAGING THEREOF Filed April 24. 1967 13 Sheets-Sheet 4 May 5, 1970 E. A. HARTBAUER ETAL 3,509,588

PROCESSING CARTONS FOR PACKAGING THEREOF' Filed April 24. 1967 1a sheets-sheet 5 May 5, 1970 E. A. HARTBAUER ETAL 3,509,688

V PROCESSING' CARTONS FOB PACKAGING THEREOF A Filed April 24. 19e? 1s sheets-sheet e May 5, 1970 E, A, HARTBAUER ET AL 3,509,688

PROCESSING CARTONS FOR PACKAGING THEREOF Filed April 24. 1967 1s sheets-sheet v 13 Sheets-Sheet 8 E. A. HARTBAUER ETAI- PRocEssING cARToNs FOR PACKAGING THEREOF Filed April 24. 196'? May 5, 1970 May 5, 1970 E. A. HARYTBAUER ETAL 3,509,688 L PROCESSING CARTONS FOR PACKAGING THEREOF Filed April 24. 196'? 13 Sheets-Sheet 9 FIG- l2 -/4- FIG- /3 /a /ag /07 w May 5, 1970 E. A. HARTBAUER ETAL 3,509,688

PROCESSING CARTONS FOR PACKAGINGTHEREOF Filed April 24. 1967 13 Sheets-Sheet l0 May 5, 1970 E. A. HARTBAUER ETAL 3,509,688

PROCESSING CARTONS FOR PACKAGING THEREOF" Filed April 24. 1967 13 Sheets-Sheet ll May 5, 1970 E. A. HARTBAur-:Fe ETAL 3,509,638

PROCESSING CRTONS FOR PACKAGING THEREOF' Filed April 24. 19e? 1s sheets-sheet 12 May 5, 1970 E. A. HARTBAUER ETAL l, 3,509,688

PROCESSING cARToNs FOR PACKAGING THEREOF l Filed April 24. 1967 13 sheets-sheet 1s United States Patent O 3,509,688 PROCESSING CARTONS FOR PACKAGING THEREOF Ellsworth A. Hartbauer, Antioch, Henry W. Rehr and Donald F. Kowalick, Concord, Calif., and John W. Wyatt, Auburn, Ala., assignors to Crown Zellerbach Corporation, San Francisco, Calif., a corporation of Nevada Filed Apr. 24, 1967, Ser. No. 633,157 Int. Cl. B651 35/40 U.S. Cl. 53-163 19 Claims ABSTRACT F THE DISCLOSURE Method of and apparatus for handling cartons of facial tissue prior to packaging the same in shipping containers therefor. Such handling involves transient storage of individual cartons in metal receptacles called tote boxes each of which is sufficiently large to hold a great number of cartons; and the apparatus employed in such handling includes a tote box loader operative to till each such tote box with facial tissue cartons for storage thereof, and further includes a tote box unloader for subsequently removing facial tissue cartons from tote boxes preparatory to packaging the cartons in shipping containers therefor. Such transient storage of facial tissue cartons prior to packaging thereof enables cartons containing variously colored tissue to be accumulated so as to permit cartons respectively containing tissue of different color to be packaged in a single shipping container.

The method includes the step of group processing cartons of facial tissue so that a plurality of cartons are handled at a time; and in this respect, loading of a tote box with cartons comprises collecting the same group-by-group to form a layer thereof and then placing the collected cartons VWithin a box layer-by-layer. Subsequently, the cartons are unloaded from the tote boxes layer-by-layer, and cartons of one color are assembled with cartons of different colors for eventual packaging as mixed lots in shipping containers therefor.

This invention relates to a method of and apparatus for packaging cartons of paper facial tissue in shipping containers ir cases therefor; and, in greater particularity, the invention relates to group processing facial tissue cartons for transient storage thereof preparatory to packaging mixed-lot cases of colored facial tissue.

For many years paper facial tissue has been packaged in cartons for sale to the consumer through retail outlets; and until quite recently white has been the only color in which facial tissue was available. At present, however, tissue is being offered in several different colors; and although there has been consumer acceptance of all such colors, it has been found that the rate of purchase varies as between different colors, This variation in rate of purchase, or sale to the consumer, has been burdensome to many retail outlets in that such outlets tend to become overstocked in certain colors in those instances where cartons containing tissue of any one color are ordered in case lots.

To avoid this situation, retailers have adopted the practice of ordering cartons of facial tissue in mixed-lot cases comprising several different colors. For example, a case of tissue may consist of 36 (24 is another common number) individual cartons, and a typical order might be for 11 cartons of `white tissue, 8 cartons of blue tissue, 7 of yellow, 6 of green, and 4 of pink. Thus, there is imposed upon the tissue manufacturer the requirement for packaging mixed-lot cases of tissue, thereby necessitating the lce availability of tissue in each of the various colors before packaging thereof can begin.

Unless several facial tissue lines are to be operated concurrentlyone for each of the various tissue colors desired (which in the usual case is not practicable), it is necessary to accumulate and store a substantial `number of cartons of each color before cartons in all of the desired colors are available for packaging thereof to form mixed-lot cases. By way of indicating the magnitude of the accumulation facilities required, a particular facial tissue line may use supply or parent rolls of paper suciently large to provide a continuous run of several hours (e.g., six or more) before the rolls are depleted and require replacement. Evidently, because of the large number (e.g., or more) of parent rolls that may supply tissue concurrently, it is economically infeasible to interrupt a run prior to depletion of the parent rolls to change the color of the tissue being processed, and clearly then this means that facilities for accumulating and storing the enormous total production of several runs must be provided before mixed-lot cases can be packaged.

The present invention is especially useful in processing cartons of facial tissue for transient storage thereof prior to such cartons being used in packaging mixed-lot cases, and in such transient storage, a great plurality of individual cartons are stored within large metal receptacles which are referred to herein as tote boxes. As respects this invention, an object thereof, among others, is to provide a method of and apparatus for group processing cartons of facial tissue and the like and for accumulating cartons group-by-group to form a layer thereof and for thereafter loading a tote box with cartons layer-by-layer. The invention further includes a method of and apparatus for unloading each such tote box layer-by-layer preparatory to packaging the cartons of facial tissue in a shipping container therefor. Additional objects and advantages of the invention, especially as concerns particular features and characteristics thereof, will become apparent as the specilication develops.

An embodiment of the invention is illustrated in the accompanying drawings in which:

FIG. 1 is a block diagram illustrating an entire box facial tissue production system embodying the invention;

FIG. 2 is a diagramatic perspective view of the tote' box loader component of the tissue production system;

FIG. 3 is a broken, transverse sectional View of the tote box loader and by-pass section therefor taken along the plane 3-3 of FIG. l;

FIG. 4 is a broken, longitudinal sectional view of the tote box loader taken along the plane 4-4 of FIG. 1;

FIG. 5 is an enlarged, longitudinal sectional view similar to that of FIG. 4 but being confined to the apparatus shown in the right hand portion thereof;

FIG. 6 is avertical sectional view through the entrance end of the tote box loader taken along the line -6-6 of FIG. 3;

FIG. 7 is a vertical sectional view, oriented transversely through the tote box loader, taken along the line 7-7 of FIG. 4;

FIG. 8 is a horizontal sectional view of the discharge end portion of the tote box loader taken along the plane 8--8 of FIG. 5;

FIG. 9 is a vertical sectional view through the entrance end of the tote box loader taken along the line 9-9 of FIG. 3;

FIG. l0 is a broken end view of the apparatus illustrated in FIG. 9 as observed from the left hand side thereof;

FIG. ll is a broken, vertical sectional view taken along the line 11-11 of FIG. 3;

FIG. 12 is an enlarged elevational view of the mechanism shown in FIG. 3 adjacent the right hand end portion of the infeed conveyor (immediately below the section line 11-11);

FIG. 13 is an end view looking from right to left of the mechanism illustrated in FIG. 12;

FIG. 14 is a vertical sectional view taken along the plane 14-14 of FIG. 13 and illustrating the abutment position of the stop structure;

FIG. l is a vertical sectional view substantially the same as that of FIG. 14 but illustrating the stop in the release position thereof;

FIG. 16 is a longitudinal sectional view taken along the plane 16-16 of FIG. 1 illustrating a tote box unloader in side elevation;

FIG. 17 is a broken, vertical sectional View taken along the line 17-17 of FIG. 16;

FIG. 18 is an enlarged vertical sectional View taken along the line 18-18 of FIG. 17;

FIG. 19 is an enlarged vertical sectional View taken along the line 19-19 of FIG. 17; and

FIG. 2O is a broken end view looking from left to right of the mechanism illustrated in FIG. 19.

GENERAL DESCRIPTION `An entire box facial tissue fabrication line is illustrated in FIG. l, and referring thereto it will be noted that such line includes a 4back stand generally denoted with the numeral 20. The back stand 20 constitutes a plurality of individual parent rolls (not shown) of tissue totaling, in the usual instance, 102 separate rolls each providing a web which is slit longitudinally as it is withdrawn from the roll into two individual webs each of facial tissue width (usually about 81/2 inches wide). The paper webs are withdrawn concurrently from the parent rolls, and as such individual webs are advanced, they are folded into the desired size and are stacked one upon another to form a longitudally extending log 21 comprising 204 individual Webs oriented in vertical juxtaposition.

The log 21 is advanced into a saw and cartoning machine 22 which severs the log transversely at spaced-apart locations therealong to section the sarne into facial tissue lengths, and then places each such section into a carton therefor which is thereafter closed and advanced along a conveyor 23. Accordingly, the conveyor 23 has disposed therealong a succession of individual cartons oriented in side-by-side juxtaposition, which cartons are denoted with thenumeral 24.

As concerns the present invention, the back stand 20, cartoning machine 22 and each of the cartons of tissue may be completely conventional and, as is well known, each such carton as a typical example, Will contain 200 double-ply tissues folded into a C-shaped or Z-shaped configuration.

Adjacent the end of the conveyor is a tote box loader 25 and also a by-pass conveyor section 26 which terminates at a diverter 27. Associated with the diverter 27 is a discharge conveyor 28 which empties into a case packer 29 operative to place a group of cartons 24 (usually totaling 36) into a shipping case. After the shipping case has been packed it can be placed upon a pallet in a palletizer 30. The case packer 29 and palletizer 30 may be conventional pieces of equipment as respects the present invention.

Whether the cartons 24 are advanced through the bypass section 26 or are advanced into the tote box loader 25 is a matter of manual selection made by an operator controlling the entire fabrication line by means of a control console 31. When the selection is such that the cartons 24 are advanced into the loader 25, the cartons are collected into individual layers comprising a plurality of transversely extending and longitudinally extending rows, and the cartons are then displaced layer-by-layer into a tote box 32 which, in the specific structure being considered, is suflciently large to receive therein 972 indi- 4 vidual cartons. After the tote box 32 has been loaded with cartons, it is advanced along a conveyor structure 33 to a pickup station 34 Where it is grasped by a storage bank loader 35 selectively movable along an elongated track 36.

Disposed along the track 36 is a storage bank 37 adapted to accommodate, in the apparatus shown, cartons containing tissue of live separate colors. For this purpose, the storage bank 37 is divided into five sections of equal capacity, which equality of capacity is not essential, respectively denoted by brackets and designated by the legends Color A through Color E. Each such section comprises a plurality of vertically stacked tiers each of which includes a plurality of tandemly disposed tote-box-receiving compartments. The storage bank loader 35 is movable along the track 36 to the pickup station 34 where it grasps a loaded tote box 32, then carries such tote box to the appropriate color section of the storage bank 37, elevates the tote box to an appropriate tier and row thereof, and finally displaces the tote box into the forvvardmost compartment of such row from which the box enters the particular compartment intended therefor.

Ultimately, the storage bank 37 will contain a-relatively large number of cartons of variously colored tissue, and a large capacity for the storage bank is required because a period of several hours of operation follows each loading of the back stand 20 with parent rolls of any one color. By way of example: a loaded back stand may accommodate a continuous period of operation of about six to eight hours, and a production line cannot practicably be changed over from the cartoning of one color to the cartoning of another until the back stand 20 is depleted. Therefore, the storage bank 37 must be able to accommodate an entire run of each of four colors (assuming a 5-color operation) before cartons containing the fth color can be packaged and shipping cases packed with cartons of each color. By Way of indicating the size of the storage bank 37, it may have a capacity of 640 tote boxes containing 622,080 cartons of facial tissue so that each such color section will have a capacity of 128 tote boxes. The particular storage bank illustrated is comprised of three separate structural components denoted 37a, 37b and 37C, but the arrangement is a matter of choice.

The number of cartons of each Color of tissue which will be packed in any one case is predetermined, and cartons in appropriate number and color in accordance with such determination are automatically delivered to the aforementioned discharge conveyor 28 by a color selector mechanism 38. The delivery of cartons to the selector 38 is effected by a plurality of infeed conveyors 39a-39e, respectively adapted to receive cartons containing the various tissue colors. The infeed conveyors 39a-39e receive cartons from a group of tote box unloaders Alla-40e respectively associated with the infeed conveyors 39a-39e. Loaded tote boxes are delivered to the unloaders 40 by the storage bank loader 35 which withdraws such tote boxes from the storage bank 37 on command from the control console 31.

After a tote box has been emptied by an unloader 40, the empty tote box is advanced along a return conveyor 41 to the tote box loader 25 Where it is available for a subsequent loading cycle. In the case where a sutlicient supply of empty tote boxes 32 is available for use at the tote box loader 25, additional empty tote boxes may be diverted onto the conveyor structure 33 for return to the c pickup station 34 from which it is deposited by the storcartons into two rows along a combining or assembly table 43 from which the cartons are advanced onto the discharge conveyor 28. As explained heretofore, the conveyor 28 advances such two rows of cartons into the case packer 29 which functions in a conventional manner to pack such cartons into a shipping case. Evidently, the diverter 27 must be conditioned selectively to receive cartons from the combining table 43 or from the by-pass section 26, since it is necessary that each of these two components deliver cartons to the discharge conveyor 28 through the diverter 27.

summarizing the operation of the box facial tissue fabrication line illustrated in FIG. 1, tissue webs are withdrawn from the parent rolls thereof provided at the back stand 20, and after being folded and stacked one upon another define an elongated log which is severed transversely into sections of carton length, each of which sections is then packaged into a carton therefor. The filled cartons are advanced in side-by-side succession toward the tote box loader which is operative to place a predetermined number of cartons in each tote -box 32. The loaded tote boxes are advanced one-by-one to the pickup station 34 from which they are deposited by the storage bank loader 35 into the storage bank 37 in the color section thereof corresponding to the color of the tissue.

When cartons having all of the necessary tissue colors are available in the storage tank 37, the storage bank loader 35 withdraws tote boxes from the storage bank and deposits each box at the appropriate tote box unloader which is operative to unload the tote box and deposit the cartons therefrom on the associated infeed conveyor 39. Thereafter the empty tote boxes are returned to the tote box loader 25 and the cartons of tissue are fed into the color selector 38 which selects and segregates the requisite number of cartons of each tissue color and combines the segregated cartons into two parallel rows, which rows are then advanced by the discharge conveyor 28 into the case packer 29. Should it be desired to bypass the tote box loader 25, storage bank 37, tote box unloaders 40 and selector 38, the cartons 24 leaving the cartoning machine 22 are directed into the by-pass section 26 which delivers such cartons directly to the discharge conveyor 28 through the diverter 27; and in this event, each case will contain cartons of one tissue color only.

TOTE BOX LOADER In initiating discussion of the tote box loader 25 and by-pass conveyor section 26 therefor, reference will be made in particular to FIG. 2 which diagrammatically illustrates the various functions of the tote box loader. As shown in this figure and as described heretofore, cartons 24 of facial tissue are advanced in side-by-side juxtaposition along the carton infeed conveyor 23, and adjacent the terminal end of such infeed conveyor is a two-position stop mechanism generally denoted 44 which in the active abutment position thereof illustrated, is engaged by advancing cartons and thereby terminates further movement thereof along the conveyor. After a predetermined number of cartons 24 have accumulated along the conveyor 23 rearwardly of the stop mechanism 44, an interrupter mechanism 45 located intermediate the tote box loader 25 and by-pass conveyor section 26 moves into gripping engagement with one or more cartons 24 in alignment therewith to prevent further movement thereof along the conveyor 23 toward the stop mechanism 44. Thereafter, a rowdisplacing pusher mechanism 46 is actuated to engage the cartons 24 then positioned between the stop mechanism 44 and interrupter mechanism 45 (which group of cartons constitute a row 47 thereof totaling 14 in the diagrammatic illustration of FIG. 2) to displace such row from the conveyor 23 and onto a stationary platform 48.

Following such displacement of a row 47 of cartons onto the platform 48, the interrupter mechanism 45 is deactuated to enable the conveyor 23 to further advance cartons 24 positioned therealong toward the stop mechanism 44 and into abutment therewith. Thereafter, the

interrupter mechanism 45 is again actuated to grip the cartons then in alignment therewith and the pusher mechanism 46 is again energized to displace a subsequent row 47 of cartons onto the platform 48. Evidently, such displacement of a subsequent row 47 will cause the prior row (or rows) then on the platform 48 to be pushed forwardly therealong, and in the illustration of FIGURE 2, six individual rows or groups 47 are located on the platform 48 and, for purposes of identification, are denoted with the numerals 47a through 47f. Such six rows or groups 47 supported upon the platform 48 together dene a layer 49 of cartons, which layer in its entirety is advanced from the platform 48 and into a tote box 32 by operation of a layer-displacing conveyor mechanism 50.

In the tote box loader 25 diagrammatically shown in FIG. 2, the layer 49 comprises eighty-four individual cartons 24 (i.e., 14 times `6) arranged in the aforementioned transversely extending rows 47 each of which is defined by a group of fourteen cartons. Each tote box 32 is adapted to receive a plurality of layers 49, and the tote box 32 shown as in the process of being loaded, has four such layers supported upon the movable bottom 51 thereof-such individual layers being denoted with the numerals 49a through 49d. For convenience of description, the tote box presently being loaded in the illustration of FIG. 2 may be considered to be located at a loading station or loading position generally indicated at 52, and after such tote box has been completely loaded, it is advanced from the station 52 along the path depicted by the directional arrow included as part of the FIG. 2 illustration. Such advancement of a loaded tote box is effected by the conveyor 33 which at the same time advances another tote box 32 into the loading station 52. Thereafter, an additional tote box is advanced into place along the conveyor 33 beneath the platform 48 so as to be ready for advancement into the loading station 52 during the next cycle of operation.

As concerns the by-pass conveyor section 26, it is ernployed whenever it is desired to bypass the tote box loader 25 and deliver cartons of tissue directly to the case packer 29. In many respects the by-pass conveyor section is quite similar to the tote box loader 2S, and it includes a twoposition stop mechanism 53 (not shown in FIG. 2, but see FIG. 3) selectively movable into an active abutment position to perform with reference to the by-pass conveyor the same function as the stop mechanism 44 with reference to the tote box loader 25. Similarly, an interrupter mechanism 54 operates in a manner analogous to that of the interrupter mechanism 45 to terminate intermittently the advancement of cartons 24 along the infeed conveyor 23 when the by-pass section 26 is being used. In further similitude with the tote box loader 25, a row displacing pusher mechanism 55 is associated with the bypass conveyor section 26, and the mechanism 55 is cyclically operable to displace successive rows or groups of cartons from intermediate the stop mechanism 53 and interrupter mechanism 54 onto the by-pass conveyor 26 which delivers the cartons row-by-row (not layer-bylayer) to the discharge conveyor 28.

The tote box conveyor 33 will now be described with particular reference being made to FIGS. 3, 4 and 5, and considering the same it is seen that the tote box conveyor 33 comprises a pair of endless chains 56 and 57 which are spaced apart transversely so as to engage a tote box 32 supported thereon along the outer edges thereof, as seen best in FIG. 3. The chain 56 is entrained about a pair of longitudinally spaced sprockets 58 and 59 and correspondingly, the chain 57 is entrained about spacedapart sprockets one of which is illustrated in FIG. 3 and is denoted with the numeral 60. the sprockets 58 and 60 are mounted upon a common shaft 61 journalled adjacent its opposite ends in bearings 62 and 63 which are resp-ectively supported by frame components `64 and 65 adapted to stand upon a suitable floor or other support surface. The upwardly extending frame components 64 and 65 are rigidied by one or more horizontally disposed frame elements 66 and, quite evidently, because of the relatively great weights of the tote boxes 32 and quantities of facial tissue cartons carried thereby, the frame components of the apparatus must be Substantial and a considerable number both of vertically disposed and of horizontally oriented frame components will be employed in the overall frame structure. lin that such frame structure and the components thereof may be essentially conventional in form and function, no specific description thereof will be made.

As shown best in FIG. 8, the sprocket 59 (and its counterpart, not shown) is mounted upon a drive shaft 61 journalled adjacent its opposite ends in bearings supported by frame components of the apparatus, one such bearing being illustrated in FIG. 8 and denoted 62. The drive shaft 61' extends outwardly from the adjacent frame components and is equipped exteriorly thereof with a sprocket 67 chain driven from a motor or other prime mover indicated by the drive sprocket 67.

Located along the conveyor chain 56 are a plurality of ,guides in the form of longitudinally spaced rollers 68 which perform two functions. First, the rollers 68 serve as stops to limit movement of each tote box 32 from the return conveyor 41 into position beneath the platform 48, and second, to guide each tote box 32 as it is moved by the tote box conveyor 33 from a position beneath the platform 48 into the loading station 52. In an analogous manner, a plurality of guides in the form of rollers 69 are located adjacent the drive shaft 61 so as to guide each tote box 32 as it is moved from the conveyor 41 and into position beneath the platform 48.

Certain associated sections of the return conveyor 41 (FIG. l) and tote box conveyor 33 are in the form of transveyors which enable the direction of movement of the tote boxes 32 to be changed by 90 at certain locations along such conveyors. Transveyors of the type used herein are commercially available and are well known in the art and need not be described in detail. Accordingly, it will only be noted herein, as is illustrated in FIG. 3, that such conveyors necessarily have sections which are substantialy normal to each other and that at each location of interconnection, one of the conveyor sections is vertically displaceable to make it dominant at certain times in control of the article moving therealong, and to make it passive at certain other times so that the coactive conveyor section then has control of such article. In this reference, the return conveyor 41 at its location of intersection with the tote box conveyor 33 is the vertically movable conveyor section and it comprises a plurality of narrow rollers 70 mounted upon elongated supports 71 which in turn are carried by the movable piston components of a plurality of spaced-apart piston-cylinder members 72 operative to displace the supports 71 and rollers 70 carried thereby between the upper and lower positions illustrated in FIG. 3 in which the rollers 70 are effective and ineffective, respectively, to control the direction of movement of each tote box supported thereabove.

The loading station 52 is defined in part by releasable stop structure operative to limit forward movement along the conveyor structure 33 of each tote box 32 and thereby positively locate each tote box within such loading station y52. The releasable stop structure is shown in FIGS. and 8 and is denoted in its entirety with the numeral 73. The stop 73 includes a roller 7-4 rotatably carried adjacent one end of a generally T-shaped lever 75 pivotally mounted adjacent another end thereof by a pin 76. The pin is supported by a stationary frame component 77, and an adjustable stop screw 78 permits selection of the precise limit of angular movement of the lever 75 in a clockwise direction about the axis of the pin 76. The lever 75 is resiliently biased toward its limiting inward position in a clockwise direction (shown in full lines in FIG. 8) by a compression spring 79 which at one end bears against the lever and at its other end bears against a fixed frame component S0. The spring 79 is a helical structure located coaxially circumjacent :a pin or plunger 81 which adjacent one end is pivotally support by the frame component and thereby accommodates pivotal displacement of the lever 75 while positively relating the spring 79 -with respect thereto.

The T-shaped lever 75 is selectively displaceable in a counterclockwise direction about the axis of the pin 76 to withdraw the roller 74 from its inner position of abutment with a tote box 32 to an outer position remote therefrom, illustrated by broken lines in FIG. 8, by a motor means 82 in the form of piston-cylinder structure, the cylinder element of which is xedly connected to the frame component 80 and the moveable piston element of which is connected to the T-shaped lever 75. Evidently, when the motor means 82 is energized, the piston and rod thereof are displaced in a direction causing counterclockwise movement of the lever 75 about the axis of the pivot pin 76 therefor to move the roller 74 into its retracted position against the biasing force of the spring 79.

Each tote box 32 is displaced along the return conveyor 41 and onto the conveyor 33 at a location beneath the platform 48 thereof by reciprocable displacement mechanism v83 comprising an elongated cylinder 84 iixedly supported by appropriate frame components of the tote box loader 25. The mechanism 83 further includes a reciprocable piston equipped with a rod or plunger which has aixed thereto a 'finger 86 adapted to engage an edge portion of a tote box 32 and thereby enforce movement thereon when the piston rod is displaced toward its innermost position.

More particularly in this respect, when a tote box 32 is moved by the return conveyor 41 into a position of alignment with the platform 48 so that it may be displaced thereunder, as shown in FIGS. 2 and 7, the plunger 85 of the cylinder 84 is in the outermost position thereof shown by broken lines in FIG. 7, wherefore movement of a tote box 32 into such position of alignment Orients the same for engagement by the finger 86'. Thereafter, energization of the cylinder 84 to displace the rod or plunger 85 toward the right, as viewed in FI-G. 7, causes the tote box .32 then in alignment with the linger 86 to be displaced along the return conveyor 41 and into position beneath the platform 48. 1t will be appreciated that during such displacement the aforementioned pistoncylinder members 72 will have been energized to elevate the rollers 70 of the return conveyor 41 into the uppermost position thereof in which the return conveyor controls movement of the tote box.

As explained hereinbefore, each tote box 32 is provided -with a movable bottom 51 adapted to receive thereon a plurality of cartons 24. The purpose of such movable bottom 51 is to enable the tote box to be loaded layerby-layer while maintaining the cartons 24 in a precise predetermined orientation relative to each other. In an analogous manner, the movable bottom 51 enables each tote box to be unloaded layer-by-layer without disturbing the predetermined orientation of the cartons 24. In this connection, the bottom 51 is shingled or has a stepped configuration which facilitates loading and unloading of the tote box by preventing misalignment or improper positioning of one or more cartons 24, which improper positioning might interfere with such layer-by-layer processing thereof. A complete and explicit explanation of such features and characteristics of the tote box are set forth in copending patent application Ser. No. 633,088 led April 24, 1967, now Pat. No. 3,421,655, and insofar as such details may find application herein, they are incorporated by such reference to this copending patent application.

Referring to FIG. 5, it will be seen that the movable bottom 51 of the tote box 32 there illustrated is in an intermediate position and has four layers 0f cartons 24 supported thereon. Such four layers are respectively dcnoted with the numerals 49a, 49h, 49a` and 49d, and each such layer comprises six transversely extending rows or groups 47 of cartons, the corresponding groups in such layers 49 being vertically juxtaposed in substantial alignment as evidenced by the numerically designated rows 49f respectively comprised by the layers 49a through 49d. Evidently, the movable bottom 51 is freely displaceable within the tote box 32, and the bottom in its lowermost position is supported perimetrically by inwardly projecting support edges provided by the tote box. Displacement of the bottom S1 through various vertical locations above such lowermost position are enforced thereon by a jack assembly 87 which is illustrated most clearly in FIG. 5.

The jack 87 is essentially a scissors type jack having pivotally interconnected levers 88 and 89 each of which comprises two separate arms or branches in the particular structure shown. At its upper and lower ends, the lever 88 is pivotally connected, respectively, to a movable floor or platform 51a through a depending ear 90 and to the frame of the tote box loader through an upwardly extending ear 91. Although supported for pivotal movement adjacent its opposite ends, the lever 88 at such ends is xed against translational displacements with respect both to the lioor 51a and to the frame of the tote box loader.

The lever 89 at its upper end is pivotally connected to the floor or platform 51a through a slot-equipped depending bracket 92 Which permits limited translational displacements of such end portion of the lever relative to the floor 51a within the limits defined by such slot. In a similar manner, the lower end of the lever 89 is pivotally connected to a frame component of the tote box loader through a slot-equipped guide or bracket 93 which permits limited translational displacement of such end portion of the lever relative to such frame. The translational displacements afforded for the end portions of the lever 89 evidently accommodate movement of the bottom 51 (i.e., oor or platform 51a which supports the bottom thereon) from the extreme lowermost position thereof (see FIG. 16), through the intermediate position shown in FIG. 5, and into an uppermost position, generally shown in FIG. 4, in which the upper surface thereof is located in substantial alignment with the platform 48.

Such movement of the oor or platform 51a is enforced thereon by a motor means 94 in the form of a fluid actuated piston-cylinder structure, the cylinder element of which is supported by a frame component of the tote box loader through a pivot pin 95 permitting angular displacement with respect thereto. The reciprocable piston of the motor means 94 is equipped with a rod or plunger 96 pivotally connected by a pin 97 to the upper branch or arm of the lever 89. Quite evidently, when the motor means 94 is energized to displace the piston rod 96 outwardly, the bottom 51 will lbe moved upwardly within the tote box 32, and reverse actuation of the motor means to displace the rod 96 inwardly will cause the bottom 51 to descend. As indicated hereinbefore, the movement of the bottom 51 is a step function related to the layer-bylayer loading and unloading of the tote box.

The infeed conveyor 23 will now be described with particular reference being made to FIGS. 2, 3, 6, 9, l and l2 through 15. The conveyor 23 includes an endless belt 98 entrained at opposite ends thereof about suitable drums, one of which is shown in the drawings (FIG. 3), and is denoted with the numeral 99. The drum 99 extends between and is rotatably supported by a pair of spaced-apart channels 100 and 101 xedly supported by the frame of the apparatus. As shown in FIG. 3, the drum 99 is driven by a pulley or sprocket 102 having a belt or chain 103 drivingly engaging the same, which chain 103 is in turn driven by a suitable motor or other prime mover, not shown. As illustrated in FIG. 6, the endless belt 98 is located intermediate the ends of the drum 99 and is sufficiently narrow that a pair of stationary rails 104 and 105 respectively extend along the opposite longitudinal edges -of the belt and tend to support each carton 24 as it is advanced thereby.

The aforementioned stop mechanism 44 is disposed adjacent the outer terminal end of the infeed conveyor 23 and, as shown best in FIGS. 12 through 15, includes an abutment plate 106 extending transversely of the infeed conveyor 23 and adapted to be engaged by the forwardmost carton 24 in a group or row thereof advancing along the conveyor. Accordingly, the abutment plate 106 defines the extreme limit of movement of cartons 24 along the conveyor 23 whenever the plate is in the carton-engaging position thereof. The abutment plate 106 is carried by a depending bar or bracket 107 which, at its upper end, is equipped with an annular hub or collar 108 supported for pivotal movements about the axis of a pin 109 between the active position illustrated in FIG. 14 in which the abutment plate 106 is in the lower cartonengaging position thereof, and the retracted position illustrated in FIG. 15 in which the abutment plate 106 is in an elevated position in which it is ineffective to engage cartons 24 advancing along the conveyor 23.

The abutment plate 106, bracket 107 and hub 108 are resiliently biased for angular movement in a counterclockwise direction, as viewed in FIG. 14, toward the retracted position of the abutment plate, shown in FIG. 15, by a helical spring 110 which at its lower end is secured to an ear 111 affixed to the bracket 107 and at its upper end is anchored to a hanger 112 affixed to a stationary frame member 113. The abutment plate 106, bracket 107 and hub 10S are ordinarily retained in the cartonengaging position, shown in FIG. 14, against the biasing force of the spring 110 by a latch 114 pivotally supported intermediate the ends thereof and adapted at one end to engage the upper edge of the bracket 107. The latch 114 is resiliently biased into its bracket-engaging position, illustrated in FIG. 14, by a helical spring 115 which at one end is connected to the latch and its upper end is aiiixed to the hanger 112.

The latch 114 is selectively movable into the release position thereof, shown in FIG. 15, against the biasing force of the spring 115 by action of a solenoid 116 supported 'by the frame member 113 and having a movable plunger pivotally connected to the latch 114 through a link 117. So long as the solenoid 1116 is de-energized, the abutment plate 106 can be maintained in the carbonengaging position thereof, shown in FIG. 14, by the latch 114 through the biasing tforce imparted thereto by the spring 115. However, energization of the solenoid 116 elevates the latch 114 to release the bracket 107, whereupon it is swung upwardly as a consequence of the biasing force imparted thereto by the spring 110. Resetting of the stop 4mechanism in the carton-engaging position thereof is a manual operation accomplished by simply swinging the abutment plate 106 and bracket 107 downwardly (an outwardly extending hand grip 118 being provided for this purpose) into the position shown in FIG. 14 whenever the solenoid 116 is de-energized.

It may be noted that in the usual case the abutment plate 106 is moved into the retracted position thereof, shown in FIG. 15, only upon malfunctioning of the tote box loader 25, by-pass conveyor section 26, or equipment lfollowing thereafter so as to permit the back stand 20 and cartoning machine 22 to continue to operate by providing a path of discharge for the cartons emanating therefrom. A push-button limit switch 119 located so as to be actuated by movement of the abutment plate 106 into the retracted position thereof (compare FIGS. 14 and 15) is included in the apparatus and it may be used in association with an indicia device to provide an indication of such positioning of the abutment plate in its elevated position.

Associated `with the stop mechanism 44 is control apparatus which includes an actuator 120 carried by a hanger 121 supported by a collar 122 circumjacent the aforementioned pin 109 for pivotal displacements with respect thereto. Also carried by the collar 122 is a camtype switch actuator 123 that is cooperatively engaged by the cam follower 124 of a switch arm 125 operative to control the condition of a limit switch 126. In this respect, the hanger 121 and actuator 120 are gravity biased into the downward position, shown by full lines in FIG. 1'2, in which a portion of the actuator 120 extends rearwardly of (to the left, as viewed in FIG. l2) the abutment plate 106 so as to be engaged by a carton moving theretoward slightly before such carton engages the abutment plate. Such condition of initial engagement of the actuator 120 by a carton 24 is illustrated in FIG. 12, and following such engagement, the actuator 120 is displaced in a counterclockwise direction, as viewed in this figure, about the axis of the pin 169. Such counterclockwise angular displacement results in the cam 123 displacing the arm 125 of the switch 126 to trip the same, thereby commencing a cycle of operation in which a group or row of cartons disposed along the conveyor 23 are displaced by the pusher mechanism 46 onto the platform 48.

As a part of such cycle of operation, the entire structural assemblage comprising the stop mechanism 44 is angularly displaced in a counterclockwise direction, as Viewed in FIGS. 12 and 14, from the normal inner position thereof shown by broken lines in FIG. 14 into its outer position illustrated by full lines in such figures so as to relieve the row of cartons 24 in engagement with the abutment plate 106 from compression by allowing the row to move through a limited distance forwardly or toward the right along the conveyor 23, which displacement of the cartons and slight relief of compression facilitate displacement thereof from the conveyor 23 and onto the platform 48. Evidently, the structural assembly cornprising the stop mechanism 44 is supported yfor such pivotal displacements by and with respect to the pin 109, and in its entirety it is biased in a counterclockwise direction by a helical spring 127 afxed at its upper end to a stationary bracket 128 and at its lower end to a bracket 129 forming a part of such mechanism 44. The extent of the angular displacement of the stop mechanism 44 in a counterclockwise direction is determined by an adjustable stop pin or screw 130.

The structural assemblage comprising the stop mechanism 44 is angularly displaced in a counterclockwise direction against the biasing force of the spring 127 to cause the abutment plate 166 to relieve a row of cartons of compression by action of a push rod 131 which at its lower end is pivotally connected to a crank arm 132 equipped at its inner end with a collar 133 supported by the pin 109 'for pivotal displacements with respect thereto. Evidently, the stop mechanism 44 is carried by such collar 133 which then affords the aforementioned permissible pivotal displacements thereof relative to the pin 109.

As shown in FIG. 3, the push rod 131 at its upper end is pivotally connected to one arrn of a bell crank 134 supported intermediate the ends thereof by a collar 135 for angular movement about a shaft 136. The other arm of such bell crank 134 is provided with a cam follower 137 that ridingly engages a cam 138 mounted upon a main drive shaft 139. Upon rotation of the shaft 139. the cam 138 is rotated and, as a consequence thereof, the push rod 131 is displaced upwardly to cause the crank arm 132, bracket 107 and abutment plate 1016- to be rotated in a clockwise direction into the position shown by broken lines in FIGURE 14 against the resilient biasing force of the spring 127.

The row-displacing pusher mechanism 46 will now be described with particular reference being made to FIGS. 2, 3, 4 and 6. The mechanism 46 is cyclically operable to displace successive rows 47 of cartons from the endless belt 98 of the infeed conveyor 23 onto the stationary platform 48; and it includes an elongated pusher bar 140 that extends longitudinally along the conveyor 23 and is of sufficient length to engage each carton defining a row 47 thereof so as to positively displace the same from the 'conveyor belt 98 and onto the platform 48. The pusher bar 140 is carried at spaced-apart locations therealong by a pair of arms 141 and 142 which are respectively connected to the bar through brackets or fasteners 143 and 144. Adjacent their upper ends, the arms 141 and 142 are clamped or otherwise secured to a shaft 145 which adjacent its opposite ends is journalled for rotation in bearing structures respectively provided by crank arms 146 and 147 clamped or otherwise iixedly secured to the aforementioned shaft 136 so as to be angularly displaced therewith.

The shaft 136 adjacent the crank arm 147 has a cam follower arm 148 secured thereto, which cam follower arm may be formed integrally with the crank arm 147 and defines a bell crank therewith. Adjacent its outer end, the arm 148 is equipped `with a rotatable cam follower 149 adapted to ridingly engage a cam 150 configured so as to displace the cam follower 149 between the inner and outer positions thereof shown in FIG. 6, such outer position being depicted in phantom by broken line. The cam 150 is mounted upon the aforementioned main drive shaft 139 so as to rotate therewith.

The pusher mechanism 46 further includes a push rod 151 pivotally secured at one end thereof to the arm 141 and at its other to the lower end of a crank arm 152 which adjacent its upper end is clamped to a shaft 153 supported adjacent its opposite ends by frame components of the apparatus in suitable journals that permit angular' displacements of the shaft. Intermediate its ends, the arm 152 is equipped with a rotatable cam follower 154 that ridingly engages a cam 155 congurated to displace the cam follower 154 between the inner and outer positions thereof depicted in FIG. 6. The cam 155 is mounted upon the aforementioned main drive shaft 139 so as to rotate therewith.

Evidently, rotation of the shaft 139 causes the cams 150 and 155 to rotate therewith, and rotation of the cam 155 results in the push rod 151 reciprocating the arms 141 and 142 and pusher bar 140 carried thereby from their outermost position, shown in full lines in FIG. 6, adjacent the outer lateral extremity of the infeed conveyor 23 to an inner position, indicated by broken lines in FIG. 6-, in which the pusher bar 140 has been moved inwardly completely across the conveyor 23 to a position above the edgev portion of the stationary platform 48. Continued rotation of the cam 155 returns the push bar 140 to its starting position. Thus, in one complete 360 rotation of the shaft 139 and cam 155 carried thereby, the pusher bar 140 is swung inwardly to displace a row `47 of cartons from the infeed conveyor 23 and onto the stationary platform 48 and is then returned to its starting position in preparation for another displacement cycle.

Concurrently therewith, simultaneous rotation of the cam 150 causes the entire pusher mechanism 46 to be displaced angularly with respect to the axis of the shaft 136 which causes the pusher bar 140 to traverse different, vertically-separated paths of travel as between the inward and outward displacements thereof. More particularly in this respect, just prior to the commencement of a cycle of operation, the pusher mechanism 46 is in the position thereof illustrated by full lines in FIG. 6, and upon initiation of such cycle, the pusher bar 140 begins to move inwardly toward engagement with the cartons defining a row 47 thereof along the infeed conveyor 23 because of the coaction of the cam 155, cam follower 154, and associated components as heretofore explained.

At the same time, coaction of the cam 150, cam follower 149, and associated components, as heretofore explained, causes the pusher bar 140 to move down- Wardly into the position denoted 140 in FIG. 6 at which position thereof the pusher bar is located at an elevation substantially along the center line of the cartons 24. The pusher bar is thereafter maintained at such elevation until it reaches its innermost position above the stationary platform 48, at which time the cam 150 causes the pusher bar to move upwardly to an elevation at which it clears any cartons 24 then disposed along the infeed conveyor to permit the -pusher bar to be returned to the starting position thereof. Such arcuate path of travel traversed by the pusher bar enables the infeed conveyor 23 to commence advancing a subsequent row 47 of cartons toward the stop mechanism 44 without having to wait until the pusher bar 140 has been returned to its starting position, thereby increasing the productive capacity of the apparatus.

In order for the row-displacing pusher machanism 46 to advance a row 47 of cartons from the conveyor 23 and onto the stationary platform 48, a minimum of interference should be presented by the successive cartons 24 being advanced along the infeed conveyor. Minimization of interference is provided in the present apparatus by interrupting advancement of cartons along the infeed conveyor during the brief interval that a row 47 of cartons is being displaced from the infeed conveyor. Such interruption is provided by the aforementioned interrupter mechanism 45 which will now be described in detail with particular reference being made to FIGS. 3, 6, 9 and 10.

The interrupter mechanism 45 comprises a pair of spaced-apart carton-gripper plate structures 156 and 157 each of which, as shown best in FIGURE l0, comprises a plurality of separate plate sections or segments, there being three in number in the structure shown and for purposes of identication such sections are respectively designated in FIG. lO with the numerals 156a, 156b and 156C. The various sections comprising each of the plate structures 156 and 157 are resiliently supported by carrier plates 158 and 159* through a plurality of helical spring and plunger devices, collectively denoted with the numeral 160, operative to urge the plate structures 156 and 157 toward each other for engagement with any cartons 24 disposed therebetween, as shown in FIG. 6 (the number of cartons so engaged depending upon the length of the plate structures, and totalling three in the particular apparatus illustrated). As will be explained hereinafter, therl springs impart a yieldable biasing force to the plate structures enabling them to grip tightly a carton 24 disposed therebetween without crushing or othenwise damaging such carton, which damage might result should the magnitude of the force imparted to the plates 156 and 157 through the carriers 158 and 159 be excessive.

The carrier plates 158 and 159 are selectively movable between an outer position illustrated in FIG. 9 in which the gripper plate structures 156 and 157 are remote from a carton 24 disposed therebetween, and an inner position shown in FIG. 6 in which such gripper plates are in engagement with a carton to prevent further movement thereof along the infeed conveyor 23. In order to accomplish such swinging movement of the carrier plates, they are respectively carried by depending arms 161 and 162 respectively supported by stub shafts 163 and 164 for pivotal displacements with respect thereto. The stub shafts are xedly mounted upon one or more frame components of the apparatus, such as the transverse frame component 165 illustrated most clearly in FIGS. 6 and 9.

Respectively secured to the stub shafts 163 and 164 are a pair of crank arms 166 and 167 in a manner preventing relative rotation therebetween, and such crank arms extend inwardly from the shafts and adjacent their inner end portions are pivotally secured by a pin 168 to the bifurcated end portion 169 of a vertically oriented push rod 170. Adjacent its upper end, the push rod 170 is pivotally connected to one end of a crank arm 171 which at its opposite end is pivotally supported by the aforementioned shaft 136, and together with a depending arm section 172 (FIG. 3) forms a bell crank equipped with a cam follower 173 that rides upon a cam 174 rotatably driven by the shaft 139. Evidently, rotation of such shaft 139 upon initiation of a cycle of operation causes the arm 171 and push rod 170 to be displaced upwardly with the result that the upward movement thereby enforced on the inner end portions of the arms 166 and 167 causes the carrier plates 158 and 159 to swing inwardly to bring the gripper plate structures 156 and 157 respectively carried thereby into carton-interrupting engagement with a carton 24 positioned therebetween.

Thereafter, as explained heretofore, inwardmovement of the pusher bar is effective to displace a row 47 of cartons from the infeed conveyor 23 without excessive frictional interference from the next successive carton positioned along the infeed conveyor. As soon as the pusher bar "140 has cleared the infeed conveyor as it moves inwardly, the cam 174 will have been rotated into a position in which the push rod will be moving downwardly to effect release of the carton 24 clamped between the plate structures 156 and 157, thereby enabling such carton and those following the same to be advanced by the conveyor 23. It will be apparent that the infeed conveyor 23 may run continuously, and the endless belt thereof simply slides beneath the cartons 24 constrained against movement therewith by action of the interrupter mechanism 45.

As shown best in FIG. 4, the cam follower 154 is resiliently maintained in engagement with the cam 155 associated therewith through a helical spring 175 which at one end is affixed to the frame of the apparatus and at its other end is aixed to an arm 176 that is clamped to the shaft 153, the spring thereby causing the arm 176 and shaft 153 to be biased in a clockwise direction, as viewed in FIGS. 4 and 6. In a similar manner, the cam follower 149 is urged into engagement with the cam 150 associated therewith by a helical spring 177 which at one end is affixed to the frame of the apparatus and at its other end is affixed to an arm 178 that is clamped to the shaft 136, the spring thereby biasing the arm 178 and shaft 136 in a counterclockwise direction, as viewed in FIGS. 4 and 6.

The main drive shaft 139 for the cams is driven through a drive train that includes a motor 179, gear reducer 180 to which it is connected by a drive belt 181 entrained about appropriate sheaves respectively carried by the motor and gear reducer, and a drive sprocket 182 mounted upon the shaft 139 and about which is entrained an endless chain 183 that is also entrained about a sprocket provided by the gear reducer 180. The motor 179 is operative to cycle the shaft 139 through one complete 360 rotation, and following any such complete revolution of the shaft, angular movement thereof terminates pending initiation of the next successive cycle of operation. Evidently, then, various control and limit switches are incorporated in the apparatus to effect such intermittently, cyclically repetitive operation of the shaft. In this reference, a one-revolution clutch can be employed as the connector between the motor 179 and gear reducer 180 in those instances where a continuously operative motor is used, although in other environments an intermittently operative motor may be employed.

As indicated hereinbefore, successive rows 47 of cartons are advanced one-by-one onto the stationary platform 48, and after a predetermined number of rows have been advanced thereonto, the entire layer 49 dened by such plurality of rows 47 is displaced in its entirety into a tote box 32 for support either directly by the movable bottom 51 thereof or indirectly thereby through a prior layer 49. The layer-displacing conveyor mechanism 50 by means of which such layer-by-layer loading of a tote box 32 is accomplished will now be described, and for this purpose reference will be made to FIGS. 1, 3 through 6 in particular.

The mechanism 50 includes a pair of endless chains 184 and 185 respectively entrained about sprockets 186, 187 and 188, 189. The chains 184 and 185 are driven 

